Rotary compressor with an installed circulation control unit

ABSTRACT

This rotary compressor with an installed circulation control unit utilizes a method to control a rotary compressor to start or stop injecting refrigerant at a predetermined velocity by means of an electromagnetic coil that is installed onto the rotary compressor. The end of the electromagnetic coil is tenon-shaped and enters into a mortise that is formed on a vane or an arm of the rotary compressor so that the operation alternates between suction and compression at a predetermined period, enabling control of the rate of refrigerant circulation. In addition, the rotary compressor does not restart during its operation, which enhances the performance of the air-conditioning system, saves costs and energy, and enables the air-conditioning system to be easily maintained and repaired.

FIELD OF INVENTION

The present invention relates to a rotary compressor and more particularly to a rotary compressor with an installed circulation control unit.

BACKGROUND OF THE INVENTION

An inverter air conditioning system is an air conditioning system the capacity of which is controlled by the volume of refrigerant circulation resulting from controlling the cycle speed of its compressor. However, such inverter compressor uses an electrical frequency method, which is technologically complicated, expensive, and difficult to repair.

Therefore, this rotary compressor with an installed circulation control unit disclosed under this patent application is developed to solve the above problems with its system being less complicated, economical, and easy to repair.

SUMMARY OF THE INVENTION

This rotary compressor with an installed circulation control unit utilizes a method to control a rotary compressor to start or stop injecting refrigerant at a designated velocity by means of an electromagnetic coil that is installed onto the rotary compressor. The tip of the electromagnetic coil is tenon-shaped and enters into a mortise that is formed on a vane that separates a compression compartment into two parts, i.e. a suction chamber and a compression chamber, so that the operation of such compression compartment alternates between suction and compression at a designated period, enabling control of the rate of refrigerant circulation.

The intention for developing this rotary compressor with an installed circulation control unit disclosed under this patent application is to control the rate of refrigerant circulation in an air-conditioning system so that the rotary compressor does not restart during its operation, which enhances the performance of the air-conditioning system, saves costs and energy, and enables the air-conditioning system to be easily maintained and repaired.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a conventional rotary compressor in a full-load operational mode.

FIG. 2 shows a conventional rotary compressor in a no-load operational mode.

FIG. 3 shows an electromagnetic coil with no supply of electric current.

FIG. 4 shows the electromagnetic coil with supply of electric current.

FIG. 5 shows the electromagnetic coil that is installed onto the rotary compressor in the first embodiment and with no supply of electric current.

FIG. 6 shows the electromagnetic coil that is installed onto the rotary compressor in the first embodiment and with supply of electric current.

FIG. 7 shows the features of a vane on which a mortise is formed and the tenon of an armature 15.

FIG. 8 shows a perspective view showing the features of a vane on which a mortise is formed and the tenon of an armature 15.

FIG. 9 shows the electromagnetic coil the armature 15 of which is altered to become shorter in length.

FIG. 10 shows the electromagnetic coil according to FIG. 9 that is installed on the rotary compressor in the second embodiment and with no supply of electric current.

FIG. 11 shows the electromagnetic coil according to FIG. 9 that is installed on the rotary compressor in the second embodiment and with no supply of electric current.

FIG. 12 is a diagram showing the rotary compressor with controllable circulation's controlled operation according to periods fixed at 50% circulation rate.

FIG. 13 is a diagram showing the rotary compressor with controllable circulation's controlled operation according to periods fixed at 75% circulation rate.

FIG. 14 shows the rotary compressor on which the electromagnetic coil is installed in the first embodiment together with an installed limit switch in a no-load operational mode.

FIG. 15 shows the rotary compressor on which the electromagnetic coil is installed in the first embodiment together with the installed limit switch in a full-load operational mode.

FIG. 16 shows the rotary compressor on which the electromagnetic coil is installed in the second embodiment together with the installed limit switch in a full-load operational mode.

FIG. 17 shows a circuit that is used for controlling the function of a coil 16.

FIG. 18 shows a side view of the rotary compressor in the first embodiment to show the positions where the electromagnetic coil and the limit switch are installed.

FIG. 19 shows the features of the vane on which the mortise is formed and modified into a notch and the tenon of the armature 15 that is modified into a slanted tooth.

FIG. 20 shows the operation of the vane on which the mortise is formed and modified into a notch and the tenon of the armature 15 that is modified into a slanted tooth.

FIG. 21 shows the electromagnetic coil that is installed on the rotary compressor in the first embodiment as well as the vane on which the mortise is formed and modified into a notch and the tenon of the armature 15 that is modified into a slanted tooth.

FIG. 22 shows the electromagnetic coil that is installed on the rotary compressor in the second embodiment as well as the vane on which the mortise is formed and modified into a notch and the tenon of the armature 15 that is modified into a slanted tooth.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A conventional rotary compressor's structure and parts contain a rolling piston 1 that is inserted on a crankshaft 2, which is inside a cylinder 3 (the cylinder and the cylinder block of the rotary compressor are in one single piece), a vane 4 that moves along a slot 5 of the cylinder 3, and a spring 6 that is contained in the slot 5 to force the vane 4 to contact with the rolling piston 1 during the rotary compressor's operation in a full-load mode.

According to FIG. 1, which shows a conventional rotary compressoris in a full-load operational mode, the vane 4 contacts with the rolling piston 1 constantly and separates a piston chamber into 2 parts, i.e. a suction chamber 7 and compression chamber 8, respectively. Therefore, when the crankshaft 2 rotates anticlockwise, the rolling piston 1 will also rotate anticlockwise. And, because of the blockage of the vane 4, a suction force is pcoreuced in the suction chamber 7 and pressure is pcoreuced in the compression chamber 8. While the rolling piston 1 is wiping to inject refrigerant, the vane 4 will move back and forth along the slot 5 by the push of the rolling piston 1, the bounce of the spring 6 and the pressure of a refrigerant injection system.

According to FIG. 2, which shows a conventional rotary compressor is in a no-load operational mode, the vane 4 is pressed into the slot 5 entirely and the piston chamber 7 and the piston chamber 8 combine to form a single chamber, i.e. a piston chamber 9, which induces a condition where there is no suction force or pressure regardless of the position of the rolling piston 1. At this stage, the rotary compressor is in a no-load operational modeoperational, which consumes the least electric current.

Based on this principle, the rotary compressor with controllable circulation disclosed under this patent application is developed and it is a development of the ability to control the operation or the opening and closing of the vane 4 by means of an electromagnetic coil that is installed onto the rotary compressor.

According to FIG. 3, which shows the structure of an electromagnetic coil 10 with no supply of electric current into a coil 16, a spring 11, which is installed between a bushing 12 and an armature 13, forces the armature 13 to slide completely inside an armature shield 14 at all time. One end of an armature core 15 is joined with the armature 13 and the other end is in a wedge form. This armature core 15 can slide back and forth along the channel of the bushing 12 as a result of the pressure of the spring 11 and the suction force of the coil 16 applied on the armature 13.

According to FIG. 4, which shows the structure of the electromagnetic coil 10 with supply of electric current into the coil 16, the armature 13 is induced to overcome the elastic force of the spring 11 and to move up to the same level as the coil 16. At the same time, the armature core 15 moves up. This method of function is then used to control the operation of the rotary compressor in several ways as further described.

According to FIG. 5, the installation of the electromagnetic coil 10 onto the rotary compressor in the first embodiment to control the opening and closing of the vane 4 is further described as follows:

The rotary compressor (as shown in FIG. 1) is bored horizontally to make a hole that is at the same level of and perpendicular to the vane 4. This hole passes through a shield 17 and the cylinder block 3 of the rotary compressor until it reaches the slot 5 where the vane 4 is installed. The size of the hole is small enough for the armature core 15 to move back and forth fitly. Then, the vane 4 is pressed into the slot 5 entirely and an area where the bored hole intersects with the vane 4 is to be observed. A mortise is then formed on this particular area of the vane 4 (as shown in FIG. 7). Then, the electromagnetic coil 10 (as shown in FIG. 3) is installed at the bored hole and welded firmly at the joint of a flange 19 (Shape may differ according to the surface of the piece to be installed.) and the shield 17 of the compressor so as to ensure that there is no leakage. The length of the armature core 15 is determined by the distance from the armature 13 in a condition where electric current is supplied to the coil 16 until the tenon of the armature 15 is inserted entirely on a mortise 18 of the vane 4, which is simultaneously pushed by the rolling piston 1 to slide into the slot 5 completely.

Because of the installation of the electromagnetic coil 10 onto the rotary compressor in the first embodiment with no supply of electric current, the vane 4 moves freely, enabling the rotary compressor to suck and compress normally. At this stage, the rotary compressor is in a full-load operational mode.

According to FIG. 6, when electric current is supplied into the coil 16 of the electromagnetic coil 10 that is installed onto the rotary compressor in the first embodiment, the armature 13 will be sucked to the same level of the coil 16 and it will push the armature core 15 upward at the same time as the rolling piston 1 pushes the vane 4 to move entirely into the slot 5, making the mortise 18 on the vane 4 to be exactly in the same line of the tenon of the armature 15. Therefore, the tenon of the armature 15 enters into the mortise 18 as a result of the push of the armature 13 and is attached to the vane 4, i.e. by attaching a side 18A to a side 15A (referring to FIG. 7 and FIG. 8) so as not to return to the piston chamber 9. At this stage, the rotary compressor is in a no-load operational mode as described in FIG. 2.

When the supply of electric current into the coil 16 stops, the spring 11 will push the armature 13 back into its shield 14 and the vane 4 will become free (according to FIG. 5). Then, the rotary compressor resumes is in a full-load operational mode and it will further alternate between no-load and full-load operational modes.

According to FIG. 9, the electromagnetic coil, which has the same structure and function as shown in FIG. 3 and FIG. 4, but the armature core 15 of which is shorter, and the shape of the flange 19 of which differs depending on the surface of the piece on which it is to be installed, is used for installation on the rotary compressor in the second embodiment to control the opening and closing of the vane 4.

According to FIG. 10 and FIG. 11, a conventional rotary compressor is connected to a connection arm 20 from the vane 4. The size of the arm 20 must be at the right size to allow insertion through the spring 21 and past the shield 17 of the rotary compressor and it should be long enough to enable installation of the electromagnetic. A tube 22 is then used to cover the arm 20 inside of which a bushing 23 supports the arm 20 to provide stability and to ensure that the arm 20 is not detached from a bushing 23 at all times even when the vane 4 slides into the piston chamber 9 entirely. Thereafter, a hole is bored on the top surface of the tube 22 between the shield 17 of the rotary compressor and the bushing 23. The electromagnetic coil 10 of FIG. 9 is further installed at this bored hole 24. Then, the vane 4 is pushed into the slot 5 entirely and the mortise 18 is to be formed on the arm 20 at the area to which the tenon of the armature core 15 points.

Thus, the length of the armature core 15 can be calculated at the period when electric current is supplied into the coil 16 and when the rolling piston 1 pushes the vane 4 inside the slot 5 entirely (as shown in FIG. 11) by measuring from the end that connects with the armature 13 to the tenon of the armature core 15 while it is inserted inside the mortise 18 of the arm 20 entirely. From this point, all joints are to be welded firmly to ensure that there is no leakage during operation, which is similar to the operation of the electromagnetic coil 10 that is installed on to the rotary compressor in the first embodiment as described above under FIG. 5 and FIG. 6.

Because of such ability to control the opening and closing of the vane 4, it is possible to control the circulation rate of refrigerant in an air-conditioning system by controlling electric current supplied into the electromagnetic coil 10 at designated periods and under the difference of room temperature as shown in the diagrams of FIG. 12 and FIG. 13.

FIG. 12 is a diagram showing control of periods of the rotary compressor according to the present invention, control of periods of electric current supply into the coil 16 in each period is shown by the diagram. According to this particular diagram, 1 period equals 20 seconds and the electric current supply stops for 10 seconds, during which the rotary compressor is in a full-load operational mode (100%). Likewise, during 10 seconds of electric current supply, the rotary compressor is in a no-load operational mode (0%). Both periods cover 20 seconds and thus the averaged value of circulation rate can be calculated as follows:

-   -   20 seconds operation in 1 period (20 seconds)=100% output     -   Thus, 10 seconds operation in 1 period (20 seconds)=50% output     -   Therefore, 1 period (20 seconds) results in 50% circulation rate         and averaged capacity of 50%.

FIG. 13 is a diagram showing control of periods of the rotary compressor according to the present invention, control of periods of electric current supply into the coil 16 in each period is shown by the diagram. According to this particular diagram, 1 period equals 20 seconds. When the electric current supply is stopped for 15 seconds and is further supplied for 5 seconds, this will result in 75% circulation rate and averaged capacity of 75%.

As mentioned above, it is clear that, the control system of an air-conditioning system that uses the rotary compressor according to the present invention never shuts the rotary compressor down during operation and the rotary compressor does not restart during operation, which saves energy that is caused by electrical surge or transient. During such operation, the system's capacity can be controlled and adjusted as needed by controlling the averaged capacity obtained from alternating between full-load and no-load operational modes in 1 period as described above.

However, during alternation from a no-load operational mode to a full-load operational mode, the vane 4 moves freely into the piston chamber 9 while the rolling piston 1 moves at high velocity, which may cause damage from a sudden impact or after being used for a certain period of time. Therefore, a limit switch 25, which is a normally closed limit switch, is attached onto the shield 17 of the rotary compressor to prevent damage from the impact between the vane 4 and the rolling piston 1.

According to FIG. 14, which shows the rotary compressor on which the electromagnetic coil 10 is installed in the first embodiment, the normally closed limit switch 25 is installed onto the shield 17 of the rotary compressor according to the present invention at a 15 to 30 degree angle from the line of the vane 4 in a direction opposite to the rotational movement of the rolling piston 1 and the center of which is situated on the center of the crankshaft 2. The shield 17 of the rotary compressor according to the present invention is further bored at this particular area until the bored hole reaches the piston chamber 9 and a size of the bored hole is exactly the same as a size of a limit arm 26. Thereafter, the limit arm 26 is inserted through this hole. The length of the limit arm 26 is determined by the length from the surface of the rolling piston 1 while pressing the limit arm 26 to the position where the limit arm 26 retracts into the hole entirely and pushes a contact plate 27 of the limit switch 25 apart (as shown in FIG. 15). With respect to such installation of the limit switch 25, firm welding between the shield of the limit switch 25 and the shield 17 of the rotary compressor is required to ensure that there is no leakage.

According to FIG. 16, which shows the rotary compressor on which the electromagnetic coil 10 is installed in the second embodiment, the normally closed limit switch 25 is also installed.

According to FIG. 17, in order to control the operation in a no-load mode, a thermostat T1 triggers the coil 16 and a contactor K0 to operate. Alternatively, a contact K1 of the contactor K0 and the contact 27 of the limit switch 25, which are serialized together, can convey electric current to trigger the coil 16 and the contactor K0.

When the operation is switched into a full-load mode, the thermostat T1 will be open but electric current can still pass through the contact K1 and the contact 27 so the coil 16 can still operate. However, when the rolling piston 1 moves to contact the limit arm 26, which causes the contact 27 to be apart as shown in FIG. 15, the coil 16 then stops operating and thus releases the vane 4 at the same time as the rolling piston 1 moves to this position at high velocity. As a result, there is no impact and the rolling piston 1 can suction and compress normally. Therefore, operation can alternate without causing any damage.

FIG. 18 shows a position of the installation of the electromagnetic coil 10 and the limit switch 25 from a side view of the rotary compressor that is perpendicular to the vane 4. In fact, the position of the electromagnetic coil 10 can be either on the left or on the right of the vane 4, and can be either higher or lower than the midpoint of the vane 4 as may be deemed appropriate.

In addition, a modification of the mortise 18 and the tenon of the armature 15 to prevent damage from the impact between the vane 4 and the rolling piston 1 instead of installing the normally closed limit switch 25 are also possible as follows:

FIG. 19 is a three-dimensional view of the structure of the armature core 15 and the vane 4 of which the mortise 18 and the tenon of the armature core 15 have been modified and the direction of movement of the armature core 15 before inserting into the mortise 18 of the vane 4.

FIG. 20 shows the structure of the armature core 15 and the vane 4 of which the mortise 18 and the tenon of the armature core 15 have been modified and a slanted tooth is formed. The tip of slanted tooth is formed on a side 15A and has a width H1 as minimal as possible to ensure that it is able to mesh without disconnecting. Then, a side 18A of the mortise is expanded towards a side 4A for a minimal width H2, which must be slightly larger than the width of the slanted tooth of the tenon of the armature core 15, and the depth of the mortise H3 is maintained throughout the expanded width H2. Then, a mortise for the slot of slanted tooth is formed on the innermost angle of a side 18B to support the tooth of the tenon of the armature core 15 with which it is to mesh, or a tooth in another shape may be formed alternatively at the tenon of the armature core 15 to mesh to the mortise on the vane 4 without disconnecting.

As a result of the mesh in this nature while the rotary compressor is in a no-load operational mode, the vane 4 is still partially inside the piston chamber 9, which enables the vane 4 to slide freely along the slot 5 as driven by the force of the rolling piston 1, the bounce of the spring 6, and the pressure of refrigerant applied on the side 4A in every cycle as long as electrical current is supplied to the coil 16, which does not adversely affect the operation.

When alternating to a full load operational mode, the electric current supplied to the coil 16 is cut off. Then, the bounce of the spring 11 forces the armature 13 back to its initial position inside the armature shield 14. However, the armature 13 is unable to retract to its initial position since the slanted tooth of the tenon of the armature core 15 still meshes to the mortise 18B that is formed on the mortise 18. When the vane 4 is pushed by the rolling piston 1 to move into the slot 5 entirely, the slanted tooth of the tenon of the armature core 15 becomes free and it detaches and moves back from the vane 4 following the movement of the armature 13 and the bounce of the spring 11. The vane 4 is then released on the top surface of the rolling piston 1 appropriately, causing no impact or damage. The operation of the rotary compressor on which the electromagnetic coil 10 is installed and the mortise 18 and the vane 4 of which are modified can alternate between full load and no-load operational modes without requiring the limit switch 25.

FIG. 21 shows the rotary compressor on which the electromagnetic coil 10 is installed in the first embodiment (as shown in FIG. 5) with modifications in the mortise 18 of the tenon of armature core 15. When no electric current is supplied into the coil 16, the tenon of the armature core 15 does not insert into the mortise 18 of the vane 4 and it moves freely following the push of the rolling piston 1, the bounce of the spring 6 and the pressure of refrigerant applied on the side 4.1. At this stage, the rotary compressor is in a full load operational mode.

However, when electric current is supplied into the coil 16, the armature 13 will overpower the bounce of the spring 11 to be in the same line with the coil 16 and the armature core 15 will move up to push the vane 4 until the rolling piston 1 pushes the vane 4 into the slot 5 entirely. The tenon of the armature core 15 enters into the mortise and is attached thereto as long as electric current is supplied to the electromagnetic coil 16. At this stage, the rotary compressor is in a no-load operational mode.

FIG. 22 shows the rotary compressor on which the electromagnetic coil 10 is installed in the second embodiment (as shown in FIG. 10) with modifications in the mortise 18 on the arm 20 and the tip of the armature core 15 that is formed to be a slanted tooth and without using the limit switch L0. When electric current is not supplied into the coil 16, the armature 13 will retract to the opening of the shield 14. However, when electric current is not supplied into the coil 16, the armature 13 will be sucked to be in the same line with the coil 16, the operational control of which is the same as that of the rotary compressor on which the electromagnetic coil is installed in the first embodiment as shown in FIG. 21.

THE BEST METHOD OF THIS INVENTION

As described in Detailed Description of The Preferred Embodiments. 

1-8. (canceled)
 9. A rotary compressor with a refrigerant flow-controlling unit capable of regulating flow of refrigerant in and out of said compressor where said controlling unit is installed onto said compressor in such a manner that moving of a vane (4) to separate a suction chamber (7) from a compression chamber (8) during an operation cycle of said compressor for a predetermined interval is controllable.
 10. A rotary compressor of claim 9, where said flow-controlling unit comprises an element (15) capable of being activated to allow its one projecting end engaging into a mortise (18) in said vane (4) to hold said vane in a predetermined position and period to make the compressor in a ‘no-load’ condition or inactivated to move said end out of said mortise to allow said compressor in a ‘full-load’ condition.
 11. A rotary compressor of claim 10 where said projecting end of said element (15) can be either in a form of simple slanted end or a slanted tooth or any shape to engage in a complementary mortise in said vane (4).
 12. A rotary compressor of claim 10 where an additional limit switch (25) is installed optionally to said compressor such that upon contact of a rolling piston (1) on an arm (26) of said switch causes detaching of contact plates (27) of said switch resulting in stop supplying of electric current into a coil (16) to make said coil (16) in ‘OFF’ position, where function of said coil (16) is to activate said element (15) when electric current is supplied to make it in ‘ON’ position.
 13. A rotary compressor of claim 9 where one set to function comprises a rolling piston (1) with a crankshaft (2) mounted in a cylinder (3) having a vane (4) movable to and fro along a slot (5) upon contacting said rolling piston or pushing of a spring (6), and where a refrigerant flow-controlling unit is installed to each of said set; and where there may be either one or multiple sets in one rotary compressor where said assembly as multiple sets helps to minimize the energy consumption as program can be set to turn on and off just one or more sets at a particular time point for a predetermined period to allow most efficient use of an air-conditioning system.
 14. A unit for controlling of flow of refrigerant in a rotary compressor comprises an element (15) capable of moving when activated to have its projecting end engage into a mortise in a vane (4) of said rotary compressor to hold said vane in a predetermined position and period, where said element housed in a structure (10, 16) to allow it to function properly.
 15. A method for controlling flow of refrigerant in a rotary compressor comprising steps of: installing a unit for controlling flow of refrigerant in and out said compressor, to be mounted through a shield (17) of at least one set to function of said compressor, activating an element (15) of said unit to move and engage its projecting end into a mortise in a vane (4) of said rotary compressor to hold said vane in a predetermined position and period.
 16. A rotary compressor of claim 10, where said flow-controlling unit alternatively comprises an element (15) capable of being activated to allow its one end engaging into a mortise (18) in a tube (22) connecting to said vane (4) to hold said vane in a predetermined position and period to make the compressor in a ‘no-load’ condition or inactivated to move said end out of said mortise to allow said compressor in a ‘full-load’ condition. 